Flexible interior trim component having an integral skin show surface

ABSTRACT

An interior trim component is provided that includes substantially parallel ribs, and a cushion coupled to the substantially parallel ribs such that the interior trim component is capable of bending in a direction substantially perpendicular to an orientation of the substantially parallel ribs. The cushion includes an integral outer skin.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of Ser. No. 13/696,778, entitled“FLEXIBLE INTERIOR TRIM COMPONENT HAVING AN INTEGRAL SKIN SHOW SURFACE”,filed Nov. 7, 2012, which is a national phase of PCT/US11/36309,entitled “FLEXIBLE INTERIOR TRIM COMPONENT HAVING AN INTEGRAL SKIN SHOWSURFACE”, filed May 12, 2011, which claims priority from and the benefitof U.S. Provisional Application Ser. No. 61/334,067, entitled “FLEXIBLEINTERIOR TRIM COMPONENT HAVING AN INTEGRAL SKIN SHOW SURFACE”, filed May12, 2010. Each of the foregoing applications is hereby incorporated byreference in its entirety.

BACKGROUND

The invention relates generally to a flexible interior trim componentfor a vehicle, having an integral skin show surface.

Vehicle storage compartments may be positioned throughout an interior ofa vehicle to store cargo and other small items. For example, an overheadconsole may include a storage compartment suitable for storingsunglasses, driving glasses, or other items. Other storage compartmentsmay be located within a center console, an armrest, seats, door panels,or other areas of the vehicle interior. Certain storage compartmentsinclude a door configured to secure the contents of the compartmentand/or hide the contents from view.

While a variety of door configurations may be employed, tambour doorsare generally well-suited for storage compartments having curvedopenings. Typical tambour doors include a series of interlocked parallelribs or segments that may rotate with respect to one another. In thismanner, the tambour door may flex in a direction perpendicular to theorientation of the parallel segments. Such a configuration may enablethe tambour door to match the contours of the curved storage compartmentopening, thereby facilitating movement of the tambour door with respectto the storage compartment opening. Unfortunately, because the ribs aregenerally constructed from substantially rigid material, the showsurface of the tambour door may be hard and/or stiff. In addition,recesses between the ribs may collect dirt and/or other contaminants,thereby degrading the appearance of the door. Alternatively, the ribsmay be coupled to a flexible carrier configured to enable the tambourdoor to bend in a direction perpendicular to an orientation of the ribs.Unfortunately, because the flexible carrier is typically constructedfrom substantially hard material, the show surface of the tambour doormay have an undesirable firmness and/or appearance.

BRIEF DESCRIPTION OF THE INVENTION

The present invention relates to an interior trim component includingmultiple substantially parallel ribs each configured to engage a trackto facilitate movement of the interior trim component along the track.The interior trim component also includes a cushion having an integralouter skin. The cushion is coupled to the substantially parallel ribs,and the integral outer skin forms a show surface of the interior trimcomponent.

The present invention also relates to an interior trim componentincluding substantially parallel ribs, and a cushion coupled to thesubstantially parallel ribs such that the interior trim component iscapable of bending in a direction substantially perpendicular to anorientation of the substantially parallel ribs. The cushion includes anintegral outer skin.

The present invention further relates to a method of manufacturing aninterior trim component including injecting resin into a first moldhaving multiple substantially parallel grooves to form correspondingsubstantially parallel ribs. The method also includes transferring thesubstantially parallel ribs to a second mold having a cavity oppositefrom the substantially parallel ribs, and pouring foam into the secondmold such that the foam forms a cushion bonded to the substantiallyparallel ribs and having an integral outer skin.

DRAWINGS

FIG. 1 is a perspective view of an exemplary vehicle that may includeone or more storage compartments each having a flexible door with anintegral skin show surface.

FIG. 2 is a perspective view of an exemplary center console that may belocated within an interior of the vehicle of FIG. 1.

FIG. 3 is a perspective view of the center console of FIG. 2 with aflexible door in an open position.

FIG. 4 is a perspective view of an exemplary flexible door with anintegral skin show surface that may be employed within the centerconsole of FIG. 2.

FIG. 5 is a cross-sectional view of a first embodiment of the flexibledoor, taken along line 5-5 of FIG. 4.

FIG. 6 is a cross-sectional view of a second embodiment of the flexibledoor, having a thicker cushion.

FIG. 7 is a detailed cross-sectional view of the flexible door,illustrating compression of the cushion and corresponding flexure of theintegral outer skin.

FIG. 8 is a perspective view of ribs formed by an injection moldingprocess, including attached runners and connectors.

FIG. 9 is a perspective view of the ribs, as shown in FIG. 8, after thecushion has been formed by pouring foam into a mold.

FIG. 10 is a process flow diagram of an exemplary process that may beutilized to form the flexible door.

FIG. 11 is a detailed cross-sectional view of an alternative embodimentof a flexible door.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of an exemplary vehicle 10, including aninterior 12 having seats 14 and a center console 16. As discussed indetail below, the center console 16 and/or other areas within theinterior 12 may include a flexible interior trim component having anintegral skin show surface, such as a flexible door enclosing a storagecompartment. For example, certain storage compartments may employ aflexible tambour door having multiple substantially parallel ribs. Theseribs may be configured to engage a track, thereby facilitating movementof the tambour door along an opening of the storage compartment. Thetambour door may also include a cushion having an interior surfacefacing an interior of the storage compartment, and an integral outerskin show surface facing the interior 12 of the vehicle 10. The interiorsurface may be coupled to the substantially parallel ribs such that thetambour door may flex in a direction perpendicular to the orientation ofthe substantially parallel ribs. Such a configuration may enable thetambour door to match the contours of a curved storage compartmentopening, thereby facilitating movement of the tambour door with respectto the storage compartment opening. As discussed in detail below, theintegral outer skin may be formed during the cushion molding process,and may serve to protect the cushion while providing a desiredappearance.

As will be appreciated, typical tambour doors include a series ofinterlocked or otherwise joined parallel ribs or segments that mayrotate with respect to one another. To facilitate tambour door segmentrotation, a recess in the show surface may be positioned adjacent toeach segment. These recesses may collect dirt and/or other contaminants,thereby degrading the appearance of the door. In addition, as thetambour door flexes, adjacent segments may rotate toward one another,thereby reducing the width of the intervening recesses. The decreasingwidth of the recesses may establish undesirable pinch points betweenadjacent segments. Furthermore, because the segments are generallyconstructed from substantially rigid material, the show surface of thetambour door may be hard and/or stiff. By providing a cushion having anintegral outer skin, the present embodiments may eliminate theserecesses and establish a soft show surface. As a result, any dirt orother contaminants which collect on the surface of the tambour door maybe easily removed. In addition, the possibility of pinching betweensegments may be substantially reduced or eliminated. Furthermore, thecushioned show surface may enable the tambour door to serve as anarmrest for vehicle occupants, thereby reducing the space utilized by aseparate armrest and storage compartment door.

FIG. 2 is a perspective view of an exemplary center console 16 that maybe located within an interior of the vehicle shown in FIG. 1. Asdiscussed in detail below, the center console 16 may include a storagecompartment enclosed by a flexible tambour door having an integral skinshow surface. As illustrated, the console 16 is coupled to a floor ofthe vehicle interior 12 between a driver seat 14 and a passenger seat14. In the present configuration, the console 16 is configured toprovide a storage area and an armrest for an occupant of one or bothseats 14. The console 16 is generally prismatic, having a front wall 18,a rear wall 20, two opposed and generally symmetrical side walls 22 anda top surface 24.

The console 16 also includes two side panels 26 which form the main bodyof the console 16. In the present configuration, each side panel 26provides one of the side walls 22 of the console 16 and portions of therear wall 20, the front wall 18 and the top surface 24. As illustrated,the side walls 22 include a compound-curved upper contour having bothconvex and concave portions, thereby transitioning between the raisedrear wall 20 and the lower front wall 18. The top edges 28 of the sidepanels 26 form the curved top surface 24. The top surface 24 includes anopening 30 that enables an occupant to access an interior of the console16. In certain configurations, the console 16 includes a rear panel 32forming a portion of the rear wall 20 and/or the top surface 24.

In the present configuration, the console 16 includes a door 34configured to transition between an open position and the illustratedclosed position. The door 34 includes a handle 38 that enables anoccupant to slide the door 34 between the two positions. As discussed indetail below, sliding the door 34 toward the open position in thedirection 40 will expose an interior of a storage compartment locatedwithin the console 16. In certain configurations, the door 34 is atambour door having a series of substantially parallel ribs coupled to acushion. The ribs are configured to engage a track within the side walls22, while the cushion enables the door 34 to flex and accommodate thecontours of the opening 30. The cushion also enables the door 34 toserve as an armrest for the vehicle occupants, thereby reducing thespace associated with providing a separate door 34 and armrest. Inaddition, the cushion includes an integral outer skin show surface toprovide a desired appearance and to protect the cushion.

While the present tambour door is described with reference to the centerconsole 16, it should be appreciated that alternative embodiments mayemploy similar tambour doors positioned throughout the interior 12 ofthe vehicle 10. For example, a storage compartment located within anoverhead console, door panel, instrument panel, or other region of theinterior 12 may include a flexible door having an integral skin showsurface. Furthermore, other flexible interior trim components, inaddition to the doors described above, may include similar parallel ribsand a cushion having an integral skin show surface. As discussed indetail below, the integral skin show surface may facilitate applicationof a decoration onto the interior trim component and/or accommodatevarious textures to enhance the appearance of the component.

FIG. 3 is a perspective view of the center console 16 of FIG. 2 with theflexible door 34 in an open position. As illustrated, the side walls 22include rails or tracks 36 configured to facilitate movement of the door34 in the direction 40. In certain configurations, the tracks 36 includea C-shaped cross section, and may be coupled to the side panels 26 orintegrally formed within the side panels 26. As discussed in detailbelow, the substantially parallel ribs of the tambour door 34 includeprotrusions which engage the tracks 36 and support the door 34, whilethe attached integral skin cushion enables the door 34 to flex, therebyaccommodating the contours of the opening 30. As illustrated,transitioning the door 34 to the open position exposes an interior 42 ofthe storage compartment within the center console 16.

As will be appreciated, a vehicle occupant may close the door 34 bygrasping the handle 38 and moving the door 34 toward the front wall 18of the center console 16. Because the surface of the door 34 facing theinterior 12 of the vehicle 10 is formed by the integral outer skin ofthe cushion, the possibility of being pinched by segments of the door 34may be substantially reduced or eliminated. Once in the closed position,the cushioned show surface of the door 34 may provide a suitable surfacefor an armrest and/or applying a decoration to the door 34 to enhancethe appearance of the vehicle interior 12.

FIG. 4 is a perspective view of an exemplary flexible door with anintegral skin show surface that may be employed within the centerconsole of FIG. 2. As illustrated, the flexible door 34 includesmultiple substantially parallel ribs 44 coupled to a padded substrate orcushion 46. The ribs 44 are configured to engage the tracks 36 of theconsole 16 to support the door 34 and to facilitate movement of the door34 across the opening 30. In the illustrated embodiment, the ribs 44include protrusions 48 configured to interlock with a correspondingrecess within each track 36. As discussed in detail below, the ribs 44are coupled to a surface of the cushion 46 facing the interior 42 of theconsole 16, thereby forming a unitary structure. In this configuration,the door 34 may flex in a direction perpendicular to the orientation ofthe substantially parallel ribs 44, thereby enabling the tambour door tomatch the contours of a curved storage compartment opening. Furthermore,the cushion 46 includes an integral outer skin that forms a show surface50 and provides a smooth, consistent appearance to the outer surface ofthe flexible door 34.

As discussed in detail below, the ribs 44 may be formed by an injectionmolding process, and may therefore be composed of any suitable materialfor injection molding. For example, the ribs 44 may be composed of athermoplastic polymer, such as polyamide, polycarbonate, oracrylonitrile butadiene styrene. It should be appreciated that the ribs44 may be composed of other materials suitable for injection molding inalterative embodiments. In addition, the ribs 44 may include a chemicalblowing agent and/or any other suitable additives.

In certain embodiments, the cushion 46 is formed by a molding process inwhich two reactive foam compounds are mixed and poured into an open moldhaving the desired shape of the cushion 46. The mold is then closed andthe mixture is allowed to expand and cure. By placing the ribs 44 intothe mold prior to pouring the foam, the foam will bond to the ribs 44during the curing process. As a result, a unitary flexible componentwill be formed. Furthermore, material chemistry as well as temperaturevariations within the mold will induce a high density flexible outerskin to form on the outer surface of the low density foam cushion. Theresulting cushion 46 will have a substantially smooth or texturedintegral outer skin, while providing sufficient flexibility to enablethe tambour door 34 to accommodate the contours of the curved storagecompartment opening 30. As discussed in detail below, a layer of paintmay be applied to the mold before the foam compounds are injected. Thepaint bonds with the foam adjacent to the inner surface of the mold,thereby establishing a desired color of the flexible outer skin. Forexample, the color of the outer skin may be selected to match the colorof a fabric seat covering.

As previously discussed, the flexible door 34 may include a handleconfigured to facilitate movement of the door 34 between the open andclosed positions. The handle may be attached to the door 34 by fasteners(e.g., bolts, screws, etc.) or injection molded along with the ribs 44.In configurations in which the handle is formed by injection molding,the foam may be poured over the plastic handle to establish a consistentappearance, or poured around the handle to provide a firm gaspingsurface. As will be appreciated, alternative embodiments may employother components (e.g., knobs, recesses, etc.) in place of the handle tocontrol movement of the door 34. For example, certain embodiments mayinclude a handle formed by establishing a depression or recess into thecushion 46.

In contrast to tambour door configurations having segmented showsurfaces, the flexible door 34 of the present embodiments does notinclude separate segments that rotate relative to one another. Instead,the cushion 46 is flexible, allowing the ribs 44 to move relative to oneanother while maintaining a unitary visual appearance of the flexibledoor 34. In addition, the cushion 46 establishes a soft show surface 50,thereby enabling the tambour door 34 to serve as an armrest for vehicleoccupants. The cushion 46 also substantially reduces or eliminates therecesses between segments that may cause pinching and collection of dirtand/or other debris. Furthermore, the integral outer skin of the cushion46 may be suitable for application of a decorative layer that mayenhance the visual appearance of the tambour door 34.

FIG. 5 is a cross-sectional view of a first embodiment of the flexibledoor, taken along line 5-5 of FIG. 4. As illustrated, the ribs 44 arecoupled to a first surface 52 of the cushion 46 which faces the interior42 of the console 16. As discussed in detail below, the ribs 44 may beformed by an injection molding process. As will be appreciated,injection molding involves injecting liquid resin into a mold to form acompleted part. Once the ribs 44 have been formed, the ribs 44 may beplaced into a mold having a cavity shaped to form the cushion 46. Foammay then be poured into the mold. As the foam expands and cures, thefoam bonds to the ribs 44, thereby forming a unitary structure includingthe ribs 44 and the cushion 46. In addition, due to the materialchemistry as well as temperature variations within the mold, a highdensity flexible outer skin 54 will be formed around the low densityfoam cushion 46. The integral outer skin 54 may serve to protect thefoam cushion 46, while providing a desirable appearance to the tambourdoor 34.

A thickness 56 of the cushion 46 may be configured to facilitate bendingof the door 34 in a direction substantially perpendicular to anorientation of the substantially parallel ribs 44, while establishing acushioned surface suitable for use as a vehicle armrest. As will beappreciated, thicker cushions 46 may provide an armrest with enhancedcomfort, while thinner cushions 46 facilitate additional flexibility.For example, in certain embodiments, the thickness 56 may be greaterthan approximately 5 mm. By way of example, the thickness 56 may beapproximately between 5 to 15, 6 to 13, 7 to 11, or about 9 mm. Inaddition, a thickness 58 of the integral outer skin 54 may beparticularly selected to enable the skin to flex as the cushion 46 iscompressed. For example, the thickness of the integral outer skin 54 maybe less than approximately 2, 1.5, 1, 0.5, 0.3, 0.2, or 0.1 mm, or less.

In certain embodiments, the cavity which forms the cushion 46 may have asubstantially smooth surface, thereby establishing a substantiallysmooth show surface 50 of the integral outer skin 54. As will beappreciated, smoothness may be defined by dimensional variations withinthe show surface 50 of the cushion 46. For example, dimensionalvariations within the show surface 50 may be between approximately 0.5to 0.01, 0.3 to 0.03, 0.2 to 0.05, or about 0.1 mm. By further example,dimensional surface variations may be less than approximately 0.5, 0.3,0.2, 0.1, 0.05, 0.03, or about 0.01 mm. Such a smooth surface 50 mayenhance the appearance of the vehicle interior 12 and/or facilitateapplication of a decoration. In alternative embodiments, the cavitywhich forms the cushion 46 may have a textured surface, therebyestablishing a textured show surface 50 of the integral outer skin 54.In further embodiments, the integral outer skin 54 may simulate theappearance of a tambour door having a series of interlocked parallelsegments. For example, the cavity which forms the cushion 46 may have aseries of parallel ridges that form corresponding parallel recesses inthe integral outer skin 54. Such a configuration may provide theappearance of a segmented tambour door without creating the undesirablepinch points between segments.

In certain embodiments, the tambour door 34 may include a decorativelayer disposed onto the show surface 50 of the integral outer skin 54,and a top coat layer disposed onto the decorative layer and bonded tothe outer skin 54. The top coat layer is configured to flex with theouter skin 54 while substantially maintaining continuity across the showsurface 50. For example, the integral outer skin 54 may simulate theappearance of a fabric skin by employing a surface finish that lookslike a fabric pattern in conjunction with a textured outer skin. Such aconfiguration may increase the visual appeal of the tambour door 34,while reducing manufacturing costs compared to employing a separateskin.

FIG. 6 is a cross-sectional view of a second embodiment of the flexibledoor 34, having a thicker cushion 46. As previously discussed, thethicker cushion 46 may provide enhanced passenger comfort inconfigurations in which the tambour door 34 is used as an armrest.However, the thicker cushion 46 may reduce flexibility. Therefore, theillustrated tambour door 34 may be utilized in consoles 16 in which thetambour door 34 moves along a flat surface or along a surface having alarge radius of curvature. For example, in certain embodiments, athickness 60 of the cushion 46 may be greater than approximately 16 mm.By way of example, the thickness 60 may be approximately between 10 to20, 12 to 18, 14 to 16, or about 15 mm.

FIG. 7 is a detailed cross-sectional view of the flexible door 34,illustrating compression of the cushion 46 and corresponding flexure ofthe integral outer skin 54. As previously discussed, the cushion 46 isdisposed adjacent to the hard ribs 44, and configured to deform under aload. Consequently, if the tambour door 34 is used as an armrest withinthe vehicle interior 12, the weight of an occupant arm will bedistributed across a large area of the door 34 as the cushion 46deforms, thereby increasing occupant comfort. The integral outer skin 54is configured to flex as the cushion 46 deforms, thereby protecting thecushion 46 and providing a desired appearance.

As will be appreciated, softness of the cushion 46 may be measured bydetermining the resistance of the cushion to deformation. A variety oftests may be employed to determine the resistance to deformation of thecushion. For example, one known indentation force deflection (IFD) testmeasures the force sufficient to indent a 50 square inch cushion sectionby a fraction (e.g., 25%) of its thickness. Based on the 25% IFD test,soft materials may have a range of approximately between 6 to 24 pounds,intermediate materials may have a range of approximately between 24 to36 pounds, and hard materials may have a range of approximately between36 to 45 pounds. In certain embodiments, the cushion 46 may be composedof a material having a 25% IFD of approximately between 24 to 36 pounds.Such a softness range may provide a desired level of passenger comfort.However, it should be appreciated that alternative embodiments mayemploy cushions having a higher or lower softness to achieve the desiredproperties of the soft component.

In addition, the integral outer skin 54 may provide durability, whilemaintaining flexibility. As will be appreciated, flexibility anddurability of the integral outer skin 54 may be measured by determiningthe hardness of the constituent material. One measure of hardness is theresistance to indentation, otherwise referred to as Durometer, denotedin the Shore A scale, for example. Within the Durometer scale, materialsare generally characterized based on ranges. Hard or rigid elastomersgenerally include those having a Durometer greater than about 90 ShoreA, soft elastomers generally include those having a Durometer of about60 Shore A to about 90 Shore A, and super-soft elastomers generallyinclude those having a Durometer below about 60 Shore A. In certainembodiments, the integral outer skin 54 may have a Durometer ofapproximately between 20 to 60 Shore A. Such a configuration mayfacilitate bending of the integral outer skin 54, while maintainingdurability and smoothness of the show surface 50. However, it should beappreciated that alternative embodiments may include an integral outerskin 54 having a Durometer of less than 20 Shore A or more than 60 ShoreA.

As illustrated, an occupant finger 62 is depressing the tambour door 34in the direction 64, thereby inducing the integral outer skin 54 toflex. As illustrated, where the finger 62 contacts the tambour door 34,the outer skin 54 has translated a distance 66 in the direction 64,thereby compressing the cushion 46. As a result, a curvature is inducedwithin the integral outer skin 54. Because the integral outer skin 54 isflexible, the possibility of crack formation is substantially reduced oreliminated. Furthermore, because the cushion 46 is compressible, thetambour door 34 may be suitable for use as an armrest within the vehicleinterior 12.

FIG. 8 is a perspective view of ribs 44 formed by an injection moldingprocess, including attached runners and connectors. As previouslydiscussed, injection molding involves injecting liquid resin into a moldto form a completed part. The mold includes cavities having a shape ofthe desired components. In certain embodiments, the mold includes afirst half and a second half that are pressed together to establish thecavities. A pressurized liquid resin in then injected into the cavitiesvia a series of flow paths or grooves. The completed part is formed asthe liquid resin cures and hardens. However, residual resin remainingwithin the flow paths will cure and harden as well, leaving runners andconnectors attached to the part.

The illustrated injection molded part includes two longitudinal runners68 extending perpendicular to the ribs 44, and a series of connectors 70extending between the runners 68 and the ribs 44. The runners 68 areformed by longitudinal flow paths configured to supply resin to each rib44, while the connectors 70 are formed by flow paths extending betweenthe longitudinal flow paths and the ribs 44. In the present embodiment,the runners 68 and connectors 70 serve to hold the ribs together afterthe injection molding process is complete. Specifically, the runners 68and connectors 70 may maintain the spacing and orientation of the ribs44 as the part is transferred from the first mold to a second mold forforming the cushion 46.

FIG. 9 is a perspective view of the ribs 44, as shown in FIG. 8, afterthe cushion 46 has been formed by pouring foam into a mold. Once thepart shown in FIG. 8 has been formed, the part may be transferred to asecond mold for forming the cushion 46. In certain embodiments, thesecond mold may include a series of recesses configured to accept theribs 44 formed by the injection molding process. In such embodiments,the recesses are aligned with a cavity having a shape of the desiredcushion 46. A layer of paint is then applied to an inner surface of themold, and two reactive compounds are mixed and poured into the mold,thereby forming the cushion 46. Due to the material chemistry as well astemperature variations within the mold, a high density flexible outerskin 54 will be formed around the low density foam cushion 46.Furthermore, the cushion 46 will bond to the ribs 44 as the foam cures.In addition, the paint will bond with the foam adjacent to the innersurface of the mold, thereby establishing a desired color of theflexible outer skin. Once the molding process is complete, the part maybe removed from the mold, and the runners 68 and connectors 70 may beremoved from the completed tambour door 34.

FIG. 10 is a process flow diagram of an exemplary process 72 that may beutilized to form the flexible door 34. First, as represented by block74, a resin is injected into a first mold having multiple substantiallyparallel grooves to form corresponding substantially parallel ribs 44.As previously discussed, the resin may be a thermoplastic polymer, suchas polyamide, polycarbonate, or acrylonitrile butadiene styrene, forexample. However, as will be appreciated, any suitable resin appropriatefor injection molding may be utilized in alternative embodiments. Theresin may be selected to form ribs 44 having sufficient bendingresistance to support the door 34 during operation.

After the first resin has cured and/or hardened, the ribs 44 may betransferred to a second mold for forming the cushion, as represented byblock 76. As previously discussed, the ribs 44 may include runners 68and connectors 70 configured to hold the ribs 44 in the desiredorientation and maintain the spacing between ribs 44. Consequently, theribs 44 may be transferred from the first mold to the second mold as asingle unit. The second mold may include recesses configured to acceptthe ribs 44, thereby aligning the ribs with a cavity that defines theshape of the cushion. Next, as represented by block 78, paint is appliedto the second mold to establish a desired color of the flexible outerskin 54 and/or to provide a layer of ultraviolet protection for thecushion 46. As previously discussed, the paint may be disposed adjacentto an inner surface of the second mold such that the paint bonds withthe portion of the poured foam that forms the outer skin 54. As aresult, the outer skin 54 may achieve a desired base color. Foam maythen be poured into the second mold to form the cushion, as representedby block 80. As previously discussed, two reactive compounds may bemixed and poured into the mold, thereby forming the cushion 46. Inaddition, due to the material chemistry as well as temperaturevariations within the mold, a high density flexible outer skin 54 willbe formed around the low density foam cushion 46. Furthermore, thecushion 46 will bond to the ribs 44 as the foam cures. Once the moldingprocess is complete, the tambour door 34 may be removed from the mold.Finally, as represented by block 82, the runners 68 and the connectors70 are removed from the completed tambour door 34.

While the cushion 46 is bonded to the ribs 44 during the curing processin the present embodiment, it should be appreciated that other bondingtechniques may be employed in alternative embodiments. For example, thecushion 46 may be molded separately from the ribs 44, and then attachedto the ribs 44 by an adhesive connection. Furthermore, while a tambourdoor 34 is described above, it should be appreciated that alternativeflexible interior trim components having an integral skin show surfacemay be utilized throughout the vehicle interior 12.

FIG. 11 is a detailed cross-sectional view of an alternative embodimentof a flexible door 34. As illustrated, an end 84 of the cushion 46 wrapsaround a protrusion 86 extending from a rib 44 positioned at alongitudinal end of the door 34. This configuration may enhance theappearance of the flexible door 34 and/or provide a stronger bondbetween the cushion 46 and the rib 44. As previously discussed, the foambonds to the ribs 44 during the foam molding process. By increasing thecontact area between the foam and a rib 44 at each longitudinal end ofthe door 34, a stronger bond will be formed, thereby enhancing thedurability of the structure. In addition, the protrusion 86 includesmultiple apertures 88 extending along the width of the door 34. As thefoam expands during the molding process, the foam will enter theapertures 88, thereby providing a mechanical lock between the foam andthe rib 44. This configuration may further enhance the bond between thecushion 46 and the ribs 44. While only one rib 44 includes a protrusion86 having apertures 88 in the illustrated embodiment, it should beappreciated that further embodiments may include multiple protrusionsconfigured to establish a mechanical lock between respective ribs andthe foam cushion. In alternative embodiments, the ribs 44 may beencapsulated within the foam during the molding process. Suchembodiments may also provide an enhanced bond between the ribs 44 andthe foam cushion 46.

While only certain features and embodiments of the invention have beenillustrated and described, many modifications and changes may occur tothose skilled in the art (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters (e.g., temperatures, pressures, etc.), mounting arrangements,use of materials, colors, orientations, etc.) without materiallydeparting from the novel teachings and advantages of the subject matterrecited in the claims. The order or sequence of any process or methodsteps may be varied or re-sequenced according to alternativeembodiments. It is, therefore, to be understood that the appended claimsare intended to cover all such modifications and changes as fall withinthe true spirit of the invention. Furthermore, in an effort to provide aconcise description of the exemplary embodiments, all features of anactual implementation may not have been described (i.e., those unrelatedto the presently contemplated best mode of carrying out the invention,or those unrelated to enabling the claimed invention). It should beappreciated that in the development of any such actual implementation,as in any engineering or design project, numerous implementationspecific decisions may be made. Such a development effort might becomplex and time consuming, but would nevertheless be a routineundertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure, without undueexperimentation.

1. An interior trim component, comprising: a plurality of ribs eachconfigured to engage a track to facilitate movement of the interior trimcomponent along the track; and a cushion having an integral outer skin,wherein the cushion is coupled to the plurality of ribs, the cushionincludes a first portion having a first density and a second portionhaving a second density, different than the first density, the firstportion and the second portion are formed from a single foam, and thesingle foam comprises at least one foam compound; wherein the firstportion extends at least partially around the second portion, the firstportion forms the integral outer skin of the cushion, and the firstdensity is greater than the second density.
 2. The interior trimcomponent of claim 1, wherein a thickness of the cushion is configuredto facilitate bending of the interior trim component in a directionsubstantially perpendicular to an orientation of the plurality of ribs.3. The interior trim component of claim 1, wherein a thickness of thecushion is greater than approximately 5 mm.
 4. The interior trimcomponent of claim 1, wherein the integral outer skin has a hardness ofgreater than approximately 20 Shore A Durometer and less thanapproximately 60 Shore A Durometer.
 5. The interior trim component ofclaim 1, wherein the interior trim component is configured tosubstantially enclose a storage compartment.
 6. The interior trimcomponent of claim 1, wherein the cushion is composed of a materialhaving a softness of greater than approximately 24 pounds and less thanapproximately 36 pounds on a 25% indentation force deflection scale. 7.The interior trim component of claim 1, comprising a decorative layerdisposed onto the integral outer skin.
 8. The interior trim component ofclaim 7, comprising a top coat layer disposed onto the decorative layerand bonded to the integral outer skin, wherein the top coat layer isconfigured to flex with the integral outer skin while substantiallymaintaining continuity across the show surface.
 9. An interior trimcomponent, comprising: a plurality of ribs; and a cushion coupled to theplurality of ribs such that the interior trim component is capable ofbending in a direction substantially perpendicular to an orientation ofthe plurality of ribs, wherein the cushion includes a first portionhaving a first density and a second portion having a second density,different than the first density, the first portion and the secondportion are formed from a single foam, and the single foam comprises atleast one foam compound; wherein the first portion extends at leastpartially around the second portion, the first portion forms an integralouter skin of the cushion, and the first density is greater than thesecond density.
 10. The interior trim component of claim 9, wherein theinterior trim component comprises a tambour door configured tosubstantially enclose a storage compartment.
 11. The interior trimcomponent of claim 9, wherein the cushion is wrapped around a protrusionextending from a rib positioned at a longitudinal end of the interiortrim component.
 12. The interior trim component of claim 9, wherein atleast one rib includes a protrusion having an aperture configured tomechanically lock the at least one rib to the cushion.
 13. The interiortrim component of claim 9, wherein each of the plurality of ribs isconfigured to engage a track to facilitate movement of the interior trimcomponent along the track.
 14. An interior trim component, comprising: aplurality of ribs each configured to engage a track to facilitatemovement of the interior trim component along the track; and a cushionhaving an integral outer skin forming a show surface of the interiortrim component, wherein the cushion is coupled to the plurality of ribs,the cushion is formed from pourable foam, the integral outer skin isformed from the pourable foam of the cushion, and a first density of theintegral outer skin is greater than a second density of the cushion. 15.The interior trim component of claim 14, wherein a thickness of thecushion is greater than approximately 5 mm.
 16. The interior trimcomponent of claim 14, wherein the integral outer skin has a hardness ofgreater than approximately 20 Shore A Durometer and less thanapproximately 60 Shore A Durometer.
 17. The interior trim component ofclaim 14, wherein the cushion is composed of a material having asoftness of greater than approximately 24 pounds and less thanapproximately 36 pounds on a 25% indentation force deflection scale. 18.The interior trim component of claim 14, comprising a decorative layerdisposed onto the integral outer skin.
 19. The interior trim componentof claim 18, comprising a top coat layer disposed onto the decorativelayer and bonded to the integral outer skin, wherein the top coat layeris configured to flex with the integral outer skin while substantiallymaintaining continuity across the show surface.
 20. The interior trimcomponent of claim 14, wherein the ribs of the plurality of ribs aresubstantially parallel to one another.